🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster 1200 Roadster

Year:

2010

Platform:

XL Sportster

Vin Prefix:

1HD

👋 Introduction

Positioning:

The 2010 Harley-Davidson Sportster 1200 Roadster was positioned as a performance-oriented, classic-styled cruiser, offering a blend of iconic Harley-Davidson aesthetics with a more aggressive riding stance and potent V-twin engine.

Competitors:

Competed against other mid-weight cruisers and performance-oriented V-twins from brands like Indian Motorcycle, Triumph, and some Japanese manufacturers offering similar displacement and style.

Design:

Dual disc front brakes, upgraded suspension components (often inverted forks), higher handlebars, solo seat, classic Sportster styling.

Target Audience:

Riders seeking a more engaging and sporty riding experience within the Harley-Davidson lineup, with an appreciation for classic styling and a focus on performance.

📋 Manual Details

Primary Coverage:

Harley-Davidson Sportster 1200 Roadster (2010)

Secondary Coverage:

Potentially covers similar Sportster models within the XL range for that era, depending on commonality of components.

Estimated Pages:

Approximately 500-700 pages (typical for a comprehensive service manual)

Type:

Service Repair Manual / Workshop Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine:

Complete overhaul, diagnostics, tuning, lubrication, cooling system, fuel injection system, exhaust system.

Transmission:

5-speed constant mesh, disassembly, assembly, adjustments, lubrication, troubleshooting.

Drivetrain:

Primary drive, belt drive system, clutch operation and service, final drive belt inspection and replacement.

Brakes:

Hydraulic disc brakes (front and rear), caliper service, master cylinder overhaul, brake fluid specifications and bleeding procedures, ABS (if equipped).

Suspension:

Front fork (telescopic, possibly with cartridge internals) service, rear shock absorber replacement, adjustments, lubrication.

Electrical:

Battery, charging system (stator, regulator/rectifier), ignition system, starting system, lighting, instrumentation, wiring diagrams, fault diagnosis.

Fuel System:

Fuel tank, fuel pump, fuel injectors (EFI), throttle body, pressure regulation, diagnostic codes related to fuel delivery.

Frame And Bodywork:

Frame inspection, body panel removal and installation, seat assembly, fenders, handlebars, controls.

Wheels And Tires:

Wheel bearing service, tire inspection and replacement, tire pressure recommendations, spoke wheel maintenance (if applicable).

Maintenance:

Scheduled maintenance, oil changes, filter replacements, spark plug service, chain/belt adjustments, brake fluid flushes, battery checks.

Troubleshooting:

Diagnostic charts, symptom-based problem solving, electrical system troubleshooting, engine performance issues.

Repair:

Step-by-step repair instructions for all major components and systems, including engine rebuilds, transmission overhauls, suspension repairs.

Overhaul:

Detailed procedures for complete disassembly and reassembly of engine, transmission, and other key sub-assemblies.

Specifications:

Torque values, clearances, fluid capacities, electrical specifications, diagnostic trouble codes (DTCs).

Rebuild Engine:

Detailed procedures for engine disassembly, inspection of internal components (pistons, rings, valves, crankshaft), reassembly with torque specifications and clearances.

Transmission Overhaul:

Complete teardown and rebuild instructions for the 5-speed transmission, including gear inspection, bearing replacement, and shift mechanism service.

Depth:

Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds. Assumes a baseline of mechanical knowledge.

Diagnostics:

Includes procedures for reading diagnostic trouble codes (DTCs), component testing (e.g., sensors, actuators), and troubleshooting electrical system faults using wiring diagrams.

Level Of Detail:

Professional technician level, providing detailed diagrams, specifications, and step-by-step instructions for complex repairs.

📊 Manual Specifications

PDF Quality:

High-resolution scans or digital creation, ensuring clarity of text, diagrams, and images. Likely searchable text.

Printability:

Printable pages, allowing users to print specific sections or the entire manual for workshop use.

Binding:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

Completeness Level:

Full workshop manual covering all aspects of repair, maintenance, and diagnostics.

⚙️ Engine Specifications

Engine Type:

Evolution V-twin, air-cooled

Displacement:

1200cc (73.4 cubic inches)

Bore X Stroke:

3.50 in. x 3.81 in. (88.9 mm x 96.8 mm)

Compression Ratio:

9.7:1

Valvetrain:

Overhead valves (OHV), 2 valves per cylinder

Ignition System:

Electronic, spark ignition

Horsepower Est:

~65-70 HP (at crankshaft, estimated)

Torque Est:

~70-75 ft-lbs (at crankshaft, estimated)

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Type:

Unleaded gasoline, minimum 91 octane (95 RON)

Oil Type:

Harley-Davidson Genuine V-Twin 20W-50 or equivalent SAE 20W-50, API CI-4 rated synthetic or semi-synthetic motorcycle oil

Oil Capacity:

Approximately 3.0 quarts (2.8 liters) with filter change.

🔧 Transmission

Transmission Type:

5-speed, constant mesh, helical gears

Clutch Type:

Wet, multi-plate, diaphragm spring

Primary Drive:

Duplex chain, 34/57 ratio

Final Drive:

Belt drive, 32/65 ratio

Transmission Fluid:

Harley-Davidson Syn 3 Transmission and Primary Lubricant or equivalent SAE 85W-140 gear oil (check manual for specific recommendations)

📐 Dimensions

Length:

Approximately 87.8 inches (2230 mm)

Width Handlebar:

Approximately 35 inches (889 mm)

Height Seat:

Approximately 28.3 inches (719 mm) (laden)

Ground Clearance:

Approximately 4.2 inches (107 mm)

Dry Weight:

Approximately 546 lbs (247.7 kg)

Gvwr:

Approximately 939 lbs (426 kg)

Fuel Capacity:

3.0 gallons (11.4 liters), including 0.5 gallon (1.9 liter) reserve

Oil Capacity:

3.0 quarts (2.8 liters)

🛡️ Safety Features

Crash Test Ratings:

N/A (Motorcycles typically do not undergo standardized crash testing like automobiles)

Brakes:

Dual front disc brakes with dual-piston calipers, single rear disc brake with dual-piston caliper.

Lighting:

Halogen headlamp, LED tail lamp, front and rear turn signals.

Chassis Design:

Steel double-cradle frame designed for stability and handling.

💡 Technology Features

Audio System:

Base models typically did not feature advanced infotainment. Optional accessories or aftermarket installations common.

Display:

Analog speedometer, analog tachometer, LCD display for odometer, trip meter, clock, gear indicator, fuel level (on some models).

ABS:

Optional on certain trims/markets, not standard on all 2010 models.

Bluetooth:

Not integrated from the factory. Aftermarket solutions available.

ECU:

Engine Control Unit (ECU) for managing fuel injection, ignition timing, and diagnostics. Access to diagnostic codes is crucial for troubleshooting.

🔧 Maintenance

Oil Change:

Every 5,000 miles (8,000 km) or annually, whichever comes first.

Primary Chain Tension:

Check every 2,500 miles (4,000 km), adjust as needed.

Spark Plugs:

Inspect every 10,000 miles (16,000 km), replace as needed. (Specific plug type: NGK DCPR7E or equivalent).

Brake Fluid:

Flush and replace every 2 years regardless of mileage.

Drive Belt:

Inspect for wear and proper tension every 5,000 miles (8,000 km).

Engine Oil:

Harley-Davidson Genuine V-Twin 20W-50 or equivalent SAE 20W-50 (API CI-4 rated).

Transmission Primary Fluid:

Harley-Davidson Syn 3 Transmission and Primary Lubricant or SAE 85W-140 gear oil.

Brake Fluid:

DOT 4 hydraulic brake fluid.

Typical Concerns:

Early 2000s models sometimes experienced issues with the starter clutch or regulator/rectifier. Fueling anomalies due to early EFI tuning could be present. Belt-driven components require regular inspection. Vibration at idle can be characteristic of the V-twin engine, but excessive vibration might indicate an issue.

📚 Vehicle History

Heritage:

Harley-Davidson, founded in 1903, boasts a rich heritage in American motorcycling, known for its V-twin engines, distinctive styling, and strong rider community.

Sportster Lineage:

The Sportster model line, introduced in 1957, has evolved significantly but maintained its core identity as a sporty, accessible Harley-Davidson. The 1200cc engine has been a staple for decades.

Roadster Variant:

The 'Roadster' designation within the Sportster line typically signifies a focus on sportier handling and performance enhancements compared to other Sportster models, often featuring upgraded suspension and brakes.

Production Location:

United States (typically Kansas City, Missouri or York, Pennsylvania)

🏆 Awards & Recognition

Industry Awards:

Sportster models, in general, have been lauded for their iconic status and performance. Specific awards for the 2010 1200 Roadster are not prominently documented, but the Sportster line consistently receives positive reviews for its blend of performance and classic styling.